University Of Gujrat

BSc Mechanical Engineering Technology

Workshop Technology
(METL-113)
Assignment - 01

Submitted by : Moeez Raza

Roll. No : 24013386-013
Submitted To : Mr. Luqman Razzaq
Date: : Oct 14, 2024

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 Assignment - 01
Research:
How different Materials Effect the Milling Process (Feed Rate, Spindle Speed,
Cutting Tools)
The Milling Process, which involves the cutting and shaping of materials using rotary cutters, can
be significantly affected by properties of the materials being machined. Different materials have distinct
physical, chemical, and mechanical properties, and these properties influence how they respond to the
Milling Process.

Here are some materials that respond differently from each other in Machining Process:

1. Aluminum
• Characteristics
o Softness: Relatively soft and ductile
o Thermal Conductivity: High thermal Conductivity, which helps dissipate heat.
o Chips: Forms Long, Continues chips
• Feed Rate
o 0.1 – 0.5 mm/tooth
o Higher feed rates are achievable due to aluminum’s machinability and lower
cutting resistance, allowing for faster processing time.
• Spindle Speed:
o 3000 – 6000 rpm
o Aluminum can be machined at high speed, leading to better surface finishes.
Higher speeds help reduce cutting forces.
• Cutting Tools
o Material: Carbide or high speed Steel(HSS) tools are commonly used
o Coating: Coating like Tim (Titanium Nitride) enhance to be a resistance and
longevity

2. Mild Steel
• Characteristics
o Hardness: Harder than Aluminum but softer than hardened steels
o Strength: Good Tensile Strength
o Chips: Forms short, manageable chips
• Feed Rate:
o 0.05 – 0.02 mm/tooth
o A balanced rate ensures efficient material removal while minimising tools train
and heat generation.
• Spindle Speed

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 o 1500 – 3000 rpm
o Moderates spindle speeds help prevent excessive tool wear and overheating.
• Cutting Tools
o Material: HSS or carbide tools are effective for machining mild steel
o Coating: Coated tools may enhance cutting performance and tool life
3. Stainless Steel
• Characteristics
o Hardness: High hardness and toughness
o Thermal Conductivity: Low thermal conductivity, leading to heat concentration
at the cutting edge
o Chips: Tends to form work- hardened chips

• Feed Rate
o 0.02 – 0.1 mm/tooth
o Lowers help ensure tool longevity and surface quality, minimising the risk of
overheating and tool damage
• Spindle Speed
o 1000 – 2000 rpm
o Lower speeds are necessary to manage heat generation and prevent work-
hardening for material
• Cutting Tools
o Material: carbide tools are preferred due to their hardness and we
resistance
o Coating: TiAlN (titanium aluminum nitride) coatings are affecting in
reducing friction and enhancing tool life

4. Titanium
• Characteristics
o Hardness: High strength-to-weight ratio
o Thermal Conductivity: Very low thermal Conductivity
o Chips: Tends to form sticky, long chips
• Feed Rate
o 0.02 – 0.1 mm/tooth
o A cautious feed rate is necessary to manage chip formation and prevent tool
breakage especially given titanium’s toughness
• Spindle Speed
o 500 – 1500 rpm
o Low spindle speeds are required to avoid excessive heat build up and tool wear
• Cutting Tools
o Material: carbide tools with specific geometries for titanium are often necessary
o Coating: Coatings such as Tin or TiAlN help improve performance and reduce
wear

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5. Cast Iron
• Characteristics
o Brittleness: Brittle material take that breaks into small chips
o Thermal conductivity: High thermal conductivity
o Chips: Forms short, powdery chips
• Feed Rate
o 0.05 – 0.3 mm/tooth
o A balanced feed rate helps in managing cheap removal and reduces the risk of
tool damage
• Spindle Speed
o 1000 – 3000 rpm
o Moderates spindle speeds are effective for cast iron, ensuring efficient material
removal while preventing excessive tool wear
• Cutting Tools
o Materials: Carbide tools are preferred due to their ability to withstand the
abrasiveness of cast iron
o Coating: Coatings like TiCN (Titanium Carbonitride) can improve tool life and
performance
6. Plastic:
• Characteristics
o Machinability: generally easy to machine with drawing properties among
different types (e.g., thermoplastics vs. thermosetting).
o Thermal Sensitivity: Many plastics can soften or deform when exposed to heat
o Chips: Tends to Produce long, Stringy chips that can stick to the cutting tool.
• Feed Rate
o 0.2 – 0.4 mm/tooth
o Higher feed rates are usually acceptable, but care must be taken to avoid chip
buildup and potential melting
• Spindle Speed
o 2000 – 6000 rpm
o Plastic can typically be machine at relatively high spindle speeds to achieve a
good surface finish. However, excessive speed can lead to overheating and
melting.
• Cutting Tool
o Material: High Speed Steel(HSS) or carbide tools can be used, depending on the
type of plastic
o Coating: Non-stick coating may be beneficial to reduce friction and prevent
material buildup on the tool.

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Programming
Write a CNC Program to machine a custom-designed part using at least 3
Operations (e.g. Facing, Pocketing, Drilling)
Material: Aluminum

Dimensions: 150mm x 100mm x 20mm

Operations and Dimensions

1. Facing:
Operation: Remove 1mm of material from the top surface to ensure flatness and a smooth
finish.
o Final thickness: 19mm
o Tool: Face mill
o Speed: 2000 RPM
o Feed: 500 mm/min

2. Pocketing:
o Location: Center of the part
o Dimensions: 60mm x 40mm x 5mm depth
o Tool: End mill (10mm diameter)
o Speed: 1500 RPM
o Feed: 300 mm/min

3. Drilling:
• Hole 1:
o Location: 20mm from the left edge, 20mm from the bottom edge
o Diameter: 10mm
o Depth: Through hole (20mm)
o Tool: Twist drill
o Speed: 1000 RPM
o Feed: 150 mm/min
• Hole 2:
o Location: 80mm from the left edge, 20mm from the bottom edge
o Diameter: 10mm
o Depth: Through hole (20mm)
o Tool: Twist drill
o Speed: 1000 RPM
o Feed: 150 mm/min

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 • Hole 3:
o Location: 140mm from the left edge, 20mm from the bottom edge
o Diameter: 10mm
o Depth: Through hole (20mm)
o Tool: Twist drill
o Speed: 1000 RPM
o Feed: 150 mm/min

CNC Program for This Part

O1000 (PROGRAM NUMBER)

(Part: 150mm x 100mm x 20mm Aluminum)

(Tools List)

(T1: 50mm Face Mill)

(T2: 10mm End Mill)

(T3: 10mm Twist Drill)

G21 (Set units to mm)

G17 (Select XY plane)

G90 (Absolute positioning)

(--- Start Facing Operation ---)

T1 M6 (Select Tool 1 – Face Mill)

G54 (Select work offset)

S2000 M3 (Set spindle speed to 2000 RPM and start spindle)

G0 X0 Y0 (Move to start position)

G43 H1 Z5 (Apply tool length offset and move to 5mm above part)

G1 Z0 F500 (Move down to part surface at 500 mm/min)

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G1 X150 Y0 F500 (Face the first pass)

G1 X150 Y100 F500 (Move to the other end of the part)

G1 X0 Y100 F500 (Face the second pass)

G1 X0 Y0 F500 (Move back to the start position)

G0 Z5 (Retract tool)

(--- Start Pocketing Operation ---)

T2 M6 (Select Tool 2 – 10mm End Mill)

S1500 M3 (Set spindle speed to 1500 RPM and start spindle)

G0 X45 Y30 (Move to start position for pocketing)

G43 H2 Z5 (Apply tool length offset and move to 5mm above part)

G1 Z-5 F300 (Plunge into the part)

G1 X105 Y30 F300 (Pocket first pass)

G1 X105 Y70 F300 (Move to the other end of the pocket)

G1 X45 Y70 F300 (Pocket second pass)

G1 X45 Y30 F300 (Move back to the start position)

G0 Z5 (Retract tool)

(--- Start Drilling Operation ---)

T3 M6 (Select Tool 3 – 10mm Twist Drill)

S1000 M3 (Set spindle speed to 1000 RPM and start spindle)

G0 X20 Y20 (Move to first hole position)

G43 H3 Z5 (Apply tool length offset and move to 5mm above part)

G81 R5 Z-22 F150 (Cycle: Drilling, Retract to 5mm, Depth: 22mm)

G0 X80 Y20 (Move to second hole position)

G81 R5 Z-22 F150 (Cycle: Drilling, Retract to 5mm, Depth: 22mm)

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G0 X140 Y20 (Move to third hole position)

G81 R5 Z-22 F150 (Cycle: Drilling, Retract to 5mm, Depth: 22mm)

G80 (Cancel drilling cycle)

M30 (End of program)

Table of this CNC Program

Line G M X Y Z I J F S Comment
Select Units to
N10 21 mm

N20 17 Select XY
plane

N30 90 Absolute
Positioning

N40 06 Select tool- 1

face mill

Select work
N50 54 offset

N60 03 2000 Set spindle

speed and
spindle Start

N70 00 00 00 Move to start

position

N80 43 05

N90 01 00 500

Face the First

N100 01 150 00 500 Pass

Move to other
N110 01 150 100 500 end of part

Face the 2nd

N120 01 00 100 500 pass

Move to Start
N130 01 00 00 500 Position

Retract tool
N140 00 05

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N150 06 Select tool- 2
end mill

N160 03 1500 Set spindle

speed and
spindle Start
N170 00 45 30 Move to start
Position
N180 43 05 Tool Length
offset
Plunge into
N190 01 05 300 part
N200 01 105 3 300 Pocket 1st pass

N210 01 105 70 300 Move to other

end of pocket
N220 01 45 70 300 Pocket 2nd
pass
Move back to
N230 01 45 30 300 start position
N240 00 05 Retract tool

N250 06 Select tool-3

Twist Drill
N260 03 1000 Set Spindle
speed and
spindle Start
N270 00 20 20 Move to 1st
hole position
N280 43 05 Tool Length
offset
Drilling, Retract
N290 81 22 150 to 5mm, Depth:
22mm
N300 00 80 20 Move to 2nd
Hole Position
Drilling, Retract
N310 81 22 150 to 5mm, Depth:
22mm
N320 00 140 20 Move to 3rd
hole position
N330 81 22 150 Drilling, Retract
to 5mm, Depth:
22mm
N340 80 Cancel Drilling
Cycle
N350 30 End of
Pragram

Explanation of Columns:
o LINE: Line number in the G-code program.
o G: G-code command or function.
o M: M-code command or function.
o X: X-coordinate position.
o Y: Y-coordinate position.
o Z: Z-coordinate position (depth).
o I: I value (used for circular interpolation or other purposes).
o J: J value (used for circular interpolation or other purposes).
o F: Feed rate.

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 o S: Spindle speed.
o COMMENT: Descriptive comment for clarity.

Analysis
Challenges Faced during Programing & Machining

Tool Selection
Selecting the appropriate tools for the machining operations is crucial to achieving desired
tolerances and surface finishes. In this part, three tools were utilized: a 50mm face mill, a 10mm end
mill, and a 10mm twist drill. The challenges included:
• Material Compatibility: Choosing tools suitable for machining aluminum was essential. The face mill
needed to have a proper geometry and coating to prevent chip buildup and wear.
• Tool Size: The diameter of the tools affected the feed rates and the depth of cut. For instance, the
face mill’s larger diameter required careful consideration of the maximum depth of cut to avoid
excessive tool load.
• Tool Change Time: Managing tool changes in the program introduced potential downtime, impacting
production efficiency. Planning the sequence of operations efficiently minimized this challenge,
allowing for a smoother transition between different cutting tools.
• Tool Wear: Monitoring tool wear and ensuring that the tools were sharp enough to achieve the
desired surface finish was a constant concern. Dull tools can lead to poor surface quality and
dimensional inaccuracies.
• Overall, the challenges surrounding tool selection revolved around ensuring the right combination of
tool type, size, and material properties to achieve optimal machining results while maintaining
efficiency.

G and M Code Commands

Understanding and correctly implementing G and M codes in the CNC program were critical for
successful machining operations. The challenges included:

• Syntax and Format: Each G and M code has specific syntax and parameters that must be followed. A
single error in typing could lead to incorrect machine behavior. It required attention to detail to
ensure that each command was written correctly.
• Conditional Commands: Some operations required conditional commands, such as G81 for drilling
cycles, which necessitated an understanding of how to use and modify these cycles based on part
requirements.
• Programming Logic: Developing a logical flow for the G-code program was challenging, particularly
in terms of establishing the correct sequence of operations. Ensuring that the program correctly
reflected the required machining steps while accounting for safe positioning and tool changes was
paramount.

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• Error Handling: Incorporating error handling in the program, such as retracti summary ng the tool to
a safe position in case of an interruption, added complexity to the code. It required forethought
about potential failure points and how the machine should respond.
• These challenges highlighted the need for both technical knowledge of CNC programming and
practical experience to anticipate and address potential issues in real-time machining scenarios.

Machine Calibration
• Machine calibration is a critical aspect of CNC machining, impacting the accuracy and quality of
the finished part. The challenges faced in this area included:
• Initial Setup: Calibrating the machine before the machining process began was essential to
ensure accurate dimensions. This required aligning the machine’s axes and confirming that the
tool offsets were correctly set.
• Work Coordinate System: Establishing the work offset (G54) accurately was crucial for ensuring
that the machine operated within the intended work area. Any misalignment could lead to
significant dimensional errors in the finished part.
• Tool Length Offsets: Applying tool length offsets (G43) correctly was another challenge. If the
offsets were not set accurately, it could lead to the tool cutting too deep or not deep enough,
compromising the part’s dimensions.
• Continuous Monitoring: During the machining process, continuous monitoring of the machine’s
performance was necessary. Any deviations in positioning or unexpected vibrations required
immediate attention and potential recalibration, which could disrupt the workflow.
• The challenges in machine calibration underscored the importance of meticulous preparation
and constant vigilance during the machining process to ensure high precision and maintain
production quality.

In, the process of machining this part involved navigating various challenges related to tool selection,
programming, and machine calibration. Each aspect required careful consideration and planning to
ensure that the final product met the required specifications.

Deliverables
CNC Program for the Custom-Designed Part
The CNC program provided for the custom-designed part is a detailed set of instructions written in G-
code, which governs the behavior of the CNC machine throughout the machining process. This program
is essential for ensuring that the part is fabricated accurately according to specified dimensions and
operations. Below are key elements of the CNC program:

• Program Header: The program begins with an identifier (O1000) for easy reference. It specifies that
the part dimensions are 150mm x 100mm x 20mm and that the material is aluminum, which
influences the selection of machining parameters.

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• Tool List: A list of tools is provided:
o T1: 50mm Face Mill for facing the top surface of the part.
o T2: 10mm End Mill for pocketing operations.
o T3: 10mm Twist Drill for drilling holes.
• Initial Setup:
Unit Configuration: The command G21 sets the units to millimeters, ensuring all measurements are
interpreted correctly.
• Plane Selection: The command G17 selects the XY plane for machining, while G90 establishes
absolute positioning for all subsequent commands.
• Facing Operation: The program selects the face mill tool (T1) and sets the spindle speed to 2000
RPM. It then moves to the starting position and plunges down to the part surface. The tool then
performs multiple passes to face the entire top surface of the part, ensuring a flat finish. After
completion, the tool retracts to a safe height.
• Pocketing Operation: The end mill tool (T2) is selected next, and the spindle speed is set to 1500
RPM. The machine moves to the specified location for pocketing, plunges into the material, and
executes a series of movements to create a rectangular pocket. The tool efficiently cleans out the
pocket in a systematic manner, ensuring uniform depth and dimensions.
• Drilling Operation: Finally, the twist drill tool (T3) is used to drill holes at designated positions. The
program sets the spindle speed to 1000 RPM and utilizes a drilling cycle (G81) to automate the
drilling process. Each hole is drilled to a depth of 22mm, with retract cycles ensuring that the drill
returns safely to a specified height after each operation.
• End of Program: The program concludes with M30, indicating that the machining cycle is complete.
This G-code structure not only ensures precise machining but also includes safety features to
prevent damage to the tool or the machine.

Report Detailing the Design Process and CNC Program

• Introduction

The purpose of this report is to provide a comprehensive overview of the design and programming
process undertaken to create a custom part using CNC machining techniques. The part in question is a
rectangular aluminum component measuring 150mm x 100mm x 20mm. The report includes insights
into the selection of tools, programming of G-code, and challenges faced throughout the project.

Design Process

1. Specifications:

The part is designed with specific dimensions to fulfill certain functional requirements. The dimensions
of 150mm x 100mm x 20mm were chosen to create a rectangular block that can serve as a base for
further assemblies.

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 2. Material Selection:

Aluminum was selected due to its favorable machining properties, including lightweight, good strength-
to-weight ratio, and ease of cutting. These attributes make aluminum an ideal choice for CNC machining,
enabling high-speed operations without excessive wear on tools.

3. Tool Selection:

The tools selected for this machining process are:

o 50mm Face Mill (T1): Used for facing operations to achieve a smooth top surface.
o 10mm End Mill (T2): Employed for pocketing to create a rectangular cavity in the part.
o 10mm Twist Drill (T3): Utilized for drilling precise holes at specified locations.

CNC Program Development

1. G-Code Structure:

The CNC program is structured into three main sections: facing, pocketing, and drilling. Each section is
clearly labeled and organized for readability. Commands such as G21, G17, and G90 establish the
machine’s operating conditions.

2. Operation Details:
o Facing Operation: The program initiates the use of the face mill tool to flatten the part’s top
surface. Multiple passes ensure that the entire surface is machined to the required flatness.
o Pocketing Operation: Following facing, the end mill tool performs pocketing to create a
rectangular cavity. The tool plunges into the material and follows a programmed path,
ensuring precise dimensions.
o Drilling Operation: Finally, the twist drill tool creates holes at predetermined locations. The
drilling cycle (G81) automates this process, allowing for consistent hole depth and retraction
after each hole is drilled.
3. Testing and Simulation:

Prior to actual machining, the CNC program was simulated using CAD/CAM software to verify tool paths
and detect any potential collisions. This step is crucial for ensuring the program’s accuracy and safety
during machining.

Conclusion

This CNC machining project has provided valuable insights into the intricacies of designing and
programming a custom part. The process required a comprehensive understanding of machining
principles, G-code programming, and problem-solving skills to overcome challenges. The final CNC
program successfully translates the design into precise machine instructions, facilitating the efficient
production of the custom aluminum part. This project not only enhanced technical skills but also
underscored the importance of meticulous planning and execution in CNC machining.

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